Surface covering

ABSTRACT

A surface covering element adapted for disposition in covering relation to a support surface. The surface covering element includes a show surface adapted to project away from the support surface when the surface covering element is disposed across the support surface and an underside adapted to project towards the support surface when the surface covering element is disposed across the support surface. A friction enhancing coating composition is disposed in coated relation across the underside at an effective level to enhance sliding friction of the surface covering element such that the surface covering element exhibits a degree of lateral grip cross across the support surface. The friction enhancing coating composition does not permanently stick to the support surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit of and priority from U.S.Provisional Application 60/465,351 filed 25 Apr. 2003; U.S. ProvisionalApplication 60/507,023 filed 29 Sep. 2003; and U.S. ProvisionalApplication 60/507,450 filed 30 Sep. 2003. The contents of all suchpriority applications are hereby incorporated by reference herein intheir entirety.

FIELD OF THE INVENTION

[0002] The present invention relates to surface coverings and moreparticularly to systems incorporating one or more surface coveringelements adapted for installation across a supporting surface andincorporating a backing at least partially coated with a compositionadapted to enhance the coefficient of sliding friction relative to thesupporting surface. Constructions of various modular surface coveringsand methods of formation and installation are also provided.

BACKGROUND OF THE INVENTION

[0003] In the past, installation of surface coverings for floors, walls,counter tops, and the like was carried out primarily by professionalinstallers utilizing natural or man-made surface covering materialsdisposed in a substantially permanent relation over a support surface.Such installation has used constructions and techniques designed toprovide firm vertical attachment between the surface covering and thesupport surface. Such exemplary prior art constructions have includedwood plank flooring nailed or adhesively bonded to the sub-floor supportsurface, carpet and carpet tile tacked or adhesively bonded in placeover the sub-floor support surface, ceramic tile held by mortar to thesupport surface, and the like.

[0004] Recently, a trend has developed promoting decorative coveringsystems which may be quickly installed and removed. Thus, a number ofproducts have been developed which promote ease of installation. In anumber of such systems installation is simplified by elimination of thefirm vertical attachment between the covering elements and theunderlying surface. However, by eliminating the firm vertical attachmentmechanism, the possibility of slippage between the support surface andthe covering element is increased.

SUMMARY OF THE PRESENT INVENTION

[0005] The present invention provides advantages and alternatives overthe prior art by providing surface coverings adapted for installationover a support surface and which include a friction enhancingcomposition disposed across at least a portion of the underside of thesurface covering. The friction enhancing composition is substantiallynon-blocking such that it does not permanently stick to itself. Thefriction enhancing composition preferably provides a relatively lightreleasable tacky adhesion to the support surface but does notpermanently stick to the support surface. However, the frictionenhancing composition does provide substantial resistance to slidingfriction between the surface covering and the underlying supportsurface.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The accompanying drawings which are incorporated in and whichconstitute a part of this specification illustrate various exemplaryembodiments of the present invention and together with the detaileddescription set forth below serve to explain the principles of theinvention wherein:

[0007]FIGS. 1-12 are top view illustrations of exemplary geometries andpatterning arrangements for surface covering elements across asupporting surface;

[0008]FIGS. 13A-23F are cut-away side view illustrations of variousexemplary multi-layered constructions for pile-forming surface coveringelements for disposition across a sub-floor support surface each ofwhich incorporates a coating of friction-enhancing composition across anunderside surface;

[0009]FIGS. 24-24B are cut-away side view illustrations of variousdecorative covering elements incorporating a non-woven show surface anda friction enhancing coating;

[0010]FIGS. 25-25B are cut-away side view illustrations of variousdecorative covering elements incorporating a flat woven or knit showsurface and a friction enhancing back coating;

[0011]FIGS. 26-26A are cut-away side view illustrations of variousdecorative covering elements incorporating a raised pile show surfaceand a friction enhancing back coating;

[0012]FIG. 27 is a cut-away side view illustration of a decorativecovering element having a wood show surface;

[0013]FIG. 28 is a cut-away side view illustration of a decorativecovering element having a ceramic show surface;

[0014]FIG. 29 is a cut-away side illustration of a decorative coveringelement having a synthetic laminate show surface; and

[0015]FIG. 30 is an elevation view of an area rug;

[0016]FIG. 31 is a cross-sectional view taken along line 31-31 in FIG.30; and

[0017]FIGS. 32-36 illustrate various exemplary discontinuous patterns offriction-enhancing materials disposed across the underside of asurface-covering element.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0018] Exemplary embodiments of the present invention will now bedescribed by reference to the accompanying drawings, in which, to theextent possible, like reference numerals are used to designate likecomponents in the various views. In FIG. 1, an exemplary system is shownschematically in which a multiplicity of modular surface coveringelements 10 are arranged in edge to edge relation across a supportingsurface 11. As will be appreciated, the surface 11 may comprise anysurface suitable to provide support beneath the surface coveringelements 10. By way of example only, materials forming the surface 11may include plywood, drywall, wood particle board, hardwood, concrete,tile, ceramic tile, vinyl, laminate, glass, or metal such as aluminum,steel or the like. The surface 11 may define a sub-floor, wall, countertop or other surface to be covered by the surface covering elements. Inparticular, it is contemplated that the surface 11 may be a raisedaccess floor having displaceable panels for access to underlying wiringand cables. As will be appreciated, while a multiplicity of surfacecovering elements 10 are illustrated as covering the underlying surface,it is likewise contemplated that a single element such as a piece ofboard loom carpet, area rug or the like may be used.

[0019] Regardless of the support surface being covered, it iscontemplated that the surface covering elements will preferably providean aesthetically pleasing coordinated covering. Moreover, it is desiredthat the individual surface covering elements should be readilyremovable after initial placement across the subfloor so as to permitrepositioning and/or subsequent replacement as desired. In addition, theindividual surface covering elements may impart a degree of cushioningacross the surface of the subfloor being covered. Such cushioning may beparticularly desirable for floor covering installations in residentialenvironments where comfort may be at a premium.

[0020] By way of example only, FIGS. 2-12 provide schematicrepresentations of at least partial installations, rugs or layouts ofdifferent shaped surface covering elements. In particular, FIG. 2illustrates an arrangement of substantially square surface coveringelements 10 arranged in offset relation. It is believed that the use ofsuch offset placement may in some instances tend to break up theperceived continuity of the seams between the surface covering elements.As will be appreciated, the surface covering elements need not besquare. Thus, in FIG. 3, there is illustrated an arrangement ofsubstantially elongate surface covering elements 10A of generallyrectangular configuration. By way of example only, it is contemplatedthat such an arrangement may be particularly useful in the event thatthe surface covering elements are supplied in a roll form or areintended to simulate wood planking.

[0021] Aside from straight sided quadrilateral geometries, it is alsocontemplated that any number of other geometries including multisidedpolygonal geometries may also be used. It is believed that the abuttingrelation of angled edges may provide a dual benefit of facilitatingproper installation across the support surface while also tending tobreak up the perceived continuity of the seams between the surfacecovering elements.

[0022]FIGS. 4 and 5 illustrate arrangements of one exemplary geometryfor a surface covering element 10B having a double chevron on each oftwo opposing sides (preferably the upper and lower edges) and with theremaining two opposing sides being straight and parallel. As shown, suchsurface covering elements may be installed in either substantiallyaligned or staggered relation across a support surface. The doublechevrons on opposite sides of the tile are preferably complements of oneanother (i.e. they fit with an adjacent or abutting tile) such that onone side the chevrons are external chevrons which protrude outwardly ina generally convex orientation while on the other side the chevrons areinternal chevrons which are recessed in a generally concave orientation.

[0023] Of course, it is to be appreciated that any number of othergeometric configurations may also be used in formation of the surfacecovering elements. By way of example only and not limitation, FIG. 6illustrates rectangular surface covering elements 10C with a singlechevron on two opposing sides or ends. FIG. 7 shows rectangular surfacecovering elements 10D with multiple (triple) chevrons on two opposingsides or ends. FIG. 8 shows surface covering elements 10E with a singlechevron on four sides thereof, wherein the opposing chevrons arerespective external and internal chevrons. FIG. 9 shows an arrangementof surface covering elements 10F having a single lobe or curved elementon four sides thereof. FIG. 10 illustrates a plurality of triangularshaped surface covering elements 10G arranged in an offset pattern. FIG.11 illustrates a plurality of diamond shaped surface covering elements10H arranged in an offset pattern. FIG. 12 illustrates a plurality ofhexagonal surface covering elements 101.

[0024] According to the illustrated practice, each of the modularsurface covering elements is substantially identical in configuration toother surface covering elements disposed across the support surface.Such uniformity of geometry is believed to substantially reduce thecomplexity of installation which may be useful to users withoutsubstantial experience in the installation of flooring systems.According to a potentially preferred practice in installation, it iscontemplated that each of the full tiles of an installation wouldpreferably be of substantially identical shape or configuration whilepartial tiles used to fill out the edges of the installation may bemanufactured as separate edge tiles or cut from full tiles.

[0025] It is contemplated that the surface covering elements may haveeither a substantially flat outer or upper face or a substantiallythree-dimensional outer face. Various exemplary constructions of bothtwo-dimensional and three-dimensional face structures are set forth morefully hereinafter.

[0026] According to one contemplated practice, the surface coveringelements disposed across the support surface are multi-layer cushionedor hard back composite carpet tile structures including a plurality ofyarns defining an outer face projecting away from the support surface.The yarns are tufted or bonded in place relative to a backing structureof cushioned or hard back construction. The backing structuredistributes loads applied across the surface covering element andprovides dimensional stability to the structure covering element suchthat shape is maintained over time. If desired, the supporting backingstructure may include one or more layers of a cushioning material suchas foam or the like to further enhance comfort during use.

[0027] Referring to FIGS. 13A, 13B, 13C, 13D exemplary constructions ofmulti-layer cushion backed pile-forming surface covering elements foruse in overlaying relation to a subfloor support surface 111 areprovided. As illustrated, constructions 110A, 110B, 110C 110D as may beused in surface covering elements of any of the previously describedgeometries each incorporate a layered arrangement of a pile formingprimary pile fabric 112 in overlying relation to a load distributinglayer 157 which in turn is disposed in overlying relation to a layer ofcushioning material 178, such as virgin foam, or rebonded foam orcompressed particle foam which may include an optional backing layer 170of felt or the like. The underside of each construction includes afriction enhancing coating 180 (either continuous or patterned) adaptedto engage the support surface 111. The friction enhancing coating 180enhances lateral grip without permanently bonding to the support surface111.

[0028] The cushioned constructions illustrated in FIGS. 13A, 13B, 13C,13D include a load distributing layer 157. The load distributing layer157 may include a sheet of reinforcement material 158 such as glass orthe like in combination with a tie coat material 160 such as athermoplastic adhesive or thermoset adhesive, preferably a hot meltadhesive or the like to establish a bonding relationship between theprimary pile fabric 112 and any underlying cushioning material 178. Itis also contemplated that the load distributing layer may besubstantially free of any reinforcement material if desired. That is,the load distribution layer 157 may be formed substantially entirely ofone or more layers of tie coat material 160.

[0029] It is contemplated that the primary pile fabric 112 mayincorporate either a tufted or a bonded configuration (with loop and/orcut pile) as will be well known. It is also contemplated that theprimary pile fabric 112 may take on any number of other pile formingconstructions including by way of example only and not limitation,textured or flat fabrics having woven, knit, or non-woven constructions.

[0030] According to one contemplated practice, the primary pile fabric112 includes a plurality of pile-forming yarns projecting outwardly fromone side of a primary base. If the primary pile fabric 112 used in thepresent invention is a tufted construction as illustrated in FIGS. 13A,13B and 13D, the primary base is preferably made up of a primary backing122 and an adhesive pre-coat 124 such as latex or the like. As will beappreciated, the constructions illustrated in FIGS. 13A and 13B areidentical except that the pile forming yarns 121 of the embodiment shownin FIG. 13B have undergone a tip shearing or loop cutting operation toyield a cut pile construction. The construction illustrated in FIG. 13Dis, in turn, substantially identical to that of FIG. 13B butincorporating pile yarns 121′ of a high twist construction such as afrieze construction or the like which imparts substantial kink to theyarns.

[0031] In the illustrated bonded surface construction 110C (FIG. 13C),the primary pile fabric 112 includes a plurality of cut pile yarns 134implanted in an adhesive 136 such as a latex or hot melt adhesive whichis laminated to a reinforcement or substrate layer 138 of a woven ornon-woven material including fiberglass, nylon, polyester orpolypropylene. It is contemplated that this substrate layer 138 may bepre-coated with latex or other thermoplastic or thermoset materials orpolymers to permit melting adhesion with the cut pile yarns 134 upon theapplication of heat, thereby enhancing yarn stability.

[0032] Although certain embodiments may be preferred, it is to beunderstood that the primary pile fabric 112 may have differentembodiments, and the component structure of the primary carpet fabric112 is not limited. Rather it is intended that any suitable primary pilefabric having a pile forming portion and a primary base or backing maybe utilized as the primary pile fabric. By “primary base” is meant anysingle layer or composite structure including, inter alia, the commonlyused layered composite of primary backing 122 and latex pre-coat 124typically used in tufted carpet constructions and the adhesive layer 136with reinforcement substrate 138 typically used in bonded constructions.Other embodiments as may occur to those of skill in the art may, ofcourse, also be utilized. For example, in the bonded product, the pileforming yarns can be heat tacked to the substrate 138 as described inU.S. Pat. No. 5,443,881 (hereby incorporated by reference herein) topermit simplified construction of a primary carpet. Alternativeembodiments including those disclosed in U.S. Pat. No. 4,576,665 toMachell (incorporated by reference) may likewise be utilized.

[0033] In accordance with a contemplated practice, the pile yarn 120,121, 121′ or 134 of constructions 110A, 110B, 110C and 110D,respectively, is capable of being dyed or printed, such as jet dyed,flood dyed, rotary printed, or the like, by, for example, using aMillitron® jet dye machine marketed by Milliken & Company of LaGrange,Ga. Also, it is contemplated that the complete construction 110A, 110B,110C, 110D of FIGS. 13A-13D are capable of being jet dyed, rotaryprinted, or the like. For example, the exemplary construction used toform the surface covering elements are preferably capable ofwithstanding the rigors of a jet dye process including dyeing, steaming,washing, drying, and the like. Consequently, the surface coveringelements can withstand heat and humidity changes, and the yarn can bedyed or printed. For example, the yarn may be white, light colored, suchas off white or light beige, yarn dyed, solution dyed, or the like.

[0034] In accordance with at least one embodiment, it is contemplated toadd an anti-bacterial, anti-fungal or anti-microbial agent, such asALPHASAN™ silver based antimicrobial agent marketed by Milliken &Company of Spartanburg, S.C., to the latex pre-coat layer and/or to theface yarn, primary backing, tie-coat layer, reinforcement material, foamor cushion, backing, and/or friction enhancing coating or grip layer180. The ALPHASAN™ silver based anti-microbial agent can withstand heatduring processing. It is also contemplated that the face yarn may besubjected to a stain resist agent such as SCOTCH GUARD® or the like.

[0035] The yarns 120, 121, 121′ and 134 may be made of natural and/orsynthetic fibers and may be either spun, staple or filament yarns andare preferably formed from a polyamide polymer such as nylon 6 staple,nylon 6 filament, nylon 6,6 staple, or nylon 6,6 filament, availablefrom commercial sources such as DuPont in Wilmington, Del. and SolutiaFibers of St. Louis, Mo. However, other suitable natural or syntheticyarns or blends may likewise be employed as will be recognized by thoseof skill in the art. By way of example only and not limitation, othermaterials, which might be used, include polyester staple or filament,polyethylene terephthalate (PET), and polybutylene terephthalate (PBT),polyolefins, such as polyethylene and polypropylene staple or filament,rayon, polyvinyl polymers such as polyacrylonitrile, wool, and blendsthereof. A variety of deniers, plies, twist levels, air entanglement,and heatset characteristics can be used to construct the yarn.

[0036] Although it may be preferred that the yarn (or fiber) be a whiteor light color to facilitate injection dyeing or printing thereof, it isto be understood that the yarn may be of any nature and color such assolution dyed, naturally colored, and the like, and be adapted for dyeinjection printing, screen printing, transfer printing, graphicstufting, weaving, knitting, and/or the like.

[0037] According to one embodiment, the weight of the yarn within theprimary pile fabric will be about 10 ounces per square yard to about 75ounces per square yard and will more preferably be about 20 ounces persquare yard to about 60 ounces per square yard and will most preferablybe about 30-50 ounces per square yard.

[0038] In accordance with a contemplated construction illustrated inFIG. 13D, the primary pile fabric may have a face construction such as afrieze cut pile, a saxony cut pile, a loop pile, a Berber loop pile, orthe like. Such constructions provide bulk through the pile due to thefact that the terminal ends of the individual pile yarns are kinked suchthat the extended length of the yarns actually exceeds the pile height.This bulking gives rise to enhanced compressibility in the thicknessdimension of the surface covering element. Such enhanced compressibilityis believed to correlate to a generally cushioned feel by a user.

[0039] As will be appreciated, the desired depth and population densityof pile forming yarns across a surface covering element may differdepending upon the intended environment of use. In particular, it isbelieved that a deeper less populous pile construction may be desired ifthe surface covering elements are to be used in covering relation to afloor in a residential environment such as a user's home. Conversely,shorter pile which is packed closer together may be desired if thesurface covering elements are to be used in a commercial environmentsuch as an office, a hospitality environment such as a hotel, or aninstitutional environment such as schools or hospitals.

[0040] The primary backing 122 used in the tufted constructions of FIGS.13A, 13B and 13D may be a traditional woven or nonwoven structure ofpolyester or polypropylene. However, it is also contemplated thatspecialized primary backings such as non-woven structures comprisingfiberglass sandwiched between layers of polyester may be utilized in theprimary backing 122 of the tufted constructions to impart the desiredproperties relating to stability and cutability thereby potentiallyreducing or even eliminating the need for adhesive pre-coat 124.Alternative primary backing or tufting substrate embodiments aredescribed, for example, in pending U.S. patent application Ser. No.10/098,053, filed Mar. 12, 2002 the teachings of which are herebyincorporated by reference in their entirety as if fully set forthherein. It is to be understood that in the event that a nonwovenstructure is used in the primary backing, such nonwoven materials can bemade in any number of ways. By way of example, it is contemplated thatnonwoven materials may be formed by suitable mechanical, chemical orthermal processing techniques. Suitable mechanical techniques mayinclude hydro-entangling, stitch bonding, and needle punching. Suitablechemical and thermal processing techniques may include melt spinning andlike practices.

[0041] By way of example only and not limitation, according to onecontemplated practice, the primary backing 122 is a fusedmulti-component structure of a woven layer and a non-woven materialneedle punched through the woven layer, with at least a portion of thenon-woven material being a low melt or binder material which whensubjected to calendaring (pressure and heat) melts and fuses thenon-woven and woven materials to form an enhanced stability primarybacking. The woven layer is a woven polypropylene, the non-wovenmaterial is polyester, and the low melt material is low melt orco-polyester. The weight percent range of low-melt or binder materialmay range from about 10%-100% by weight of the non-woven, preferably10%-70%, most preferably 10%-40%. The non-woven material may be anynatural or synthetic fiber or blend thereof. For example, the non-wovenmay be polyester, recycled polyester, polypropylene, stabilizedpolypropylene, acrylic, nylon (polyamide), bi-component polyester,bi-component nylon, and blends or combinations thereof. If the non-wovenmaterial is a polypropylene or stabilized polypropylene, then noadditional low melt material may be required. The low melt material maybe any synthetic material or fiber or blend that has a melting pointbelow the calendaring temperature and will adhere to the adjacentfibers. For example, the binder or low melt material may be polyester,co-polyester, polypropylene, polypropylene that has been chemicallyenhanced to raise the melt temperature, bi-component polyester,bi-component nylon, polyethylene, nylon, low melt nylon web, powderbinder, chemical binder, extruded polypropylene web, and combinations orblends thereof. The woven material may be any natural or syntheticmaterial or fiber or blend which serves as a tufting base in combinationwith the non-woven and low melt materials. For example, the wovenmaterial may be polypropylene, stabilized polypropylene, flat ribbonyarn (tape) polypropylene, polyester, polyester knitted scrim,polypropylene woven scrim, recycled polyester, and blends orcombinations thereof. In accordance with one exemplary construction, thewoven layer or material may have a pick range of from about 6×6 to30×30, preferably from about 10×10 to 24×22, the non-woven material mayhave a weight range of about 1-6 oz./sq. yd., with a low melt or bindercontent of about 10-100% by weight.

[0042] In accordance with one exemplary practice, an enhanced primarybacking 122 having an overall thickness of about 0.017 inches and weightof about 5.03 oz./sq. yd. may be utilized. The primary backing includesa woven material fused to a blended needled non-woven material ofpolyester and low-melt polyester fibers (50% by weight natural polyesterfibers 2½ denier, 20% black polyester fibers 4 denier, and 30% low meltpolyester 3 denier). The primary backing is formed by placing thenon-woven material over the woven layer, needle punching the non-wovenmaterial to the woven layer such that a small amount of the non-wovengoes through the woven layer and then calendaring the composite on bothsides (at a temperature of about 320° F. top roller, 280° F. bottomroller with roller pressures of about 85 pounds force) force to fuse thenon-woven material and woven layer. This fused, enhanced stabilityprimary backing is less likely to fray when cut, does not harm thetufting yarn, provides dimensional stability, and better tuft lock.

[0043] In accordance with yet another exemplary practice, an enhancedprimary backing includes a woven scrim and nonwoven fiber needled andthen fused in accordance with the following:

[0044] Scrim: woven polypropylene (PP) 24 ends by 11 picks @ 3 oz.

[0045] Weight of Nonwoven: 1.75 oz./sq. yd.

[0046] Nonwoven content:

[0047] 30% low melt polyester (PET)—4 denier; 2″ staple length

[0048] 50% natural PET—2.25 denier; 3″ staple length

[0049] 20% black PET—4.0 denier; 4″ staple length

[0050] Calendar temperatures:

[0051] Face: 320 F.

[0052] Back: 280 F.

[0053] In tufted constructions, the adhesive pre-coat 124 is preferablystyrene butadiene rubber (SBR) or latex but other suitable materialssuch as styrene acrylate, polyvinyl chloride (PVC), ethylene vinylacetate (EVA), acrylic, and hot melt adhesives such as bitumen,polyurethane, polyester, polyamide, EVA, or asphalt based hot meltadhesives or blends thereof may likewise be utilized. In the event thata hot melt adhesive is utilized, it is contemplated that a reinforcementmaterial such as a fiberglass, nylon or polyester scrim, woven ornon-woven may be directly attached to form a composite laminate withoutthe use of additional adhesive layers. Moreover, it is contemplated thatthe adhesive pre-coat 124 may be entirely eliminated in the tuftedproduct if the pile yarn is tufted in suitably stable relation to theprimary backing 122 thereby yielding a construction as illustrated inFIGS. 15A-15C.

[0054] As previously indicated, it is contemplated that a cushion backedsurface covering element construction including either a tufted or abonded primary pile fabric 112 across the surface facing away from thesubfloor 111 may include a load distribution layer 157 at a positionbelow the primary pile fabric. By way of example only, it iscontemplated that the load distribution layer 157 may include one ormore layers of a resilient polymeric tie coat material 160. Thepolymeric tie coat material 160 may be of either a thermoplastic or athermosetting composition. Hot melt adhesives may be particularlypreferred. By way of example only and not limitation, useful hot meltsmay include bitumen and polyolefin-based thermoplastics. Usefulthermosetting adhesives may include polyurethanes. In the event that thetie coat material 160 is a hot melt adhesive, it is contemplated thatthe total mass of hot melt adhesive utilized within the loaddistribution layer 157 will preferably be in the range of about 20 toabout 100 ounces per square yard and will more preferably be present ata level of about 35 to about 90 ounces per square yard. The compositionof one potentially preferred hot melt adhesive is set forth in thefollowing table. Hot Melt Composition Component Percentage Asphalt17.6%  Stearic Acid 0.3% Heat Stabilizer 0.2% Antioxidant 0.1% Tackifier3.0% Amorphous Polypropylene 4.0% Acid Modified Polypropylene 2.0%Calcium Carbonate Filler Remainder

[0055] The physical properties of the hot melt composition from theabove table are set forth below. Hot Melt Properties Softening Point314-320° F. Cold Flow  2 to 5 mils per 4 hours Flex Mandrel 12 to 16 mmat 76 mils CR Viscosity (at 5 sec⁻¹⁾ 28,000 to 35,000 cps CS Viscosity(at 50 Tau) 10,000 to 13,000 cps Tensile Strength ˜450 p.s.i. Elongationat Break 5.8%

[0056] If desired, a reinforcement material 158 may also be disposedwithin the load distribution layer 157. In some constructions, thereinforcement material may enhance dimensional stability within thesurface covering element to substantially prevent the various layersfrom undergoing disproportionate dimensional change as the surfacecovering element is subjected to compressive forces and/or temperatureor humidity changes during use and/or processing. One contemplatedreinforcement material 158 is a sheet, mat or tissue incorporatingmultiple fiberglass (glass) fibers entangled in a non-woven constructionsuch as a 2 oz/yd² construction and may be held together by one or morebinders such as an acrylic binder or modified acrylic binder. Othermaterials as may be utilized include woven glass or glass scrimmaterials as well as woven or non-woven textile materials such aspolyester or nylon. If desired, it is also contemplated that thereinforcement material 158 may be eliminated such that the loaddistribution layer is made up substantially entirely of the tie coatmaterial.

[0057] Whether or not a reinforcement material 158 is utilized, the loaddistribution layer 157 nonetheless acts to disperse concentrated loadslaterally through the surface covering element thereby dissipating theapplied energy and preventing the structure from being damaged. Inoperation, the tie coat material 160 acts as a buffer against forceconcentration and will protect any reinforcement material 158 againstpuncture or other damage which may arise from point loading. By way ofexample, the load distribution layer must have sufficient strength andresiliency such that a small diameter shoe heel or other forceconcentrating object does not puncture the construction.

[0058] As indicated, the cushioning material 178 may be a foam material.Potentially preferred foam materials may include virgin or primepolyurethane, rebonded polyurethane and combinations thereof. Rebondedpolyurethane may be particularly preferred so as to permit the surfacecovering elements to incorporate a relatively high percentage ofrecycled material.

[0059] As will be appreciated, rebond foam in general and rebondpolyurethane foam in particular is known in the art of isocyanate-basedpolymeric foams. Specifically, it is known to mix pieces of foam with abinder which serves to bond the pieces to one another. Rebondingtechnology has been used for a number of years to recycle, inter alia,polyurethane foams. Generally, a large chip or chunk size, low density,non-uniform density, rather frangible, thick, rebonded polyurethane foamproduct has been used as a separate, relatively thick, underlayment orpad for broadloom carpet placed across a subfloor.

[0060] In accordance with one contemplated practice, the cushioningmaterial 178 in the surface covering element may incorporate about10-90% recycled foam or rebond foam containing about 10-100% recycledfoam chips, chunks, pieces, grounds, particles, or the like and abinder, adhesive, or prepolymer (and one or more additives) to produce aconstruction with an integral cushioning layer having about 10-100%recycled foam or cushion content (especially post industrial reclaimedfoam or cushion content) in the foam or cushion layer thereof.

[0061] In accordance with one contemplated practice, the cushioningmaterial may be a rebond foam with a density of about 1 to 25 lbs percubic foot, more preferably about 3-22 lbs. per cubic foot, still morepreferably 5-13 lbs. per cubic foot, and most preferably 6-10 lbs. percubic foot; a thickness of about 1-30 mm, more preferably about 2-21 mm,and most preferably about 4-12 mm; a rebond chip size (uncompressed chipsize) of about 2-25 mm, more preferably about 5-20 mm, most preferablyabout 7-15 mm round or square hole mesh; and, a backing material orbacking composite on at least one side thereof.

[0062] Table 1 below details a first exemplary range of productionparameters for rebond foam for use as a cushioning layer in a modularfloor covering to be used in a residential environment. TABLE 1 FoamWeight 7-84 oz/yd² Foam Density 4-16 lbs./ft³ Foam Thickness(prelamination) 2-20 mm Uncompressed Chip Size 2-20 mm Chip MaterialPolyurethane Foam (polyester or polyether) Binder or Prepolymer  5-20%Chips 60-95% Binder Material Polyurethane Prepolymer (polyester orpolyether) Compression Ratio 2:1-5:1 Additives such as colorant, fill,fiber,  0-20% antimicrobial, flame retardant, etc.

[0063] Table 2 below details a second exemplary range of productionparameters for rebond foam for use as a cushioning layer in a modularfloor covering to be used in a residential environment. TABLE 2 FoamWeight 10-28 oz/yd² Foam Density  5-10 lbs./ft³ Foam Thickness(prelamination)  5-12 mm Uncompressed Chip Size  5-15 mm Chip MaterialPolyurethane Foam (polyester or polyether) Binder or Prepolymer 12-17%Chips 83-88% Binder Material Polyurethane Prepolymer (polyester orpolyether) Compression Ratio 3:1 Additives such as colorant, fill,fiber,  0-5% etc.

[0064] Tables 3-5 set forth exemplary target specifications for rebondfoam materials which may be used in various modular residential floorcovering structures. TABLE 3 Foam Density 6 lbs./ft³ Foam Thickness 7-8mm (prelamination) Uncompressed Chip Size 15 mm Chip MaterialPolyurethane Foam Binder or Prepolymer 15% by weight Chips 82-85% byweight Binder Material Polyurethane Prepolymer Compression Ratio 3:1Colorant (may be added) Milliken Reactint polyurethane colorant at about3%

[0065] TABLE 4 Foam Density 6.3 lbs./ft³ Foam Thickness (prelamination)7 mm Uncompressed Chip Size 7 mm Chip Material Polyurethane Foam Binderor Prepolymer 15% by weight Chips (free of unbonded material) 82-85% byweight Binder Material (free of binder knots) Polyurethane PrepolymerCompression Ratio 3:1 Colorant (may be added) Milliken Reactintpolyurethane colorant at about 3%

[0066] TABLE 5 Foam Density 3 lbs./ft³ Foam Thickness (prelamination) 6mm Uncompressed Chip Size 5 mm Chip Material Polyurethane Foam Binder orPrepolymer 15% Chips 82-85% Binder Material Polyurethane PrepolymerCompression Ratio 2:1 Colorant (may be added) Milliken Reactintpolyurethane colorant at about 3%

[0067] As will be appreciated, while rebond foam as described above maybe used, it is also contemplated that the material forming thecushioning layer 178 may be the subject of a broad range ofalternatives. By way of example only and not limitation, at least fiveoptions or examples of foam for use in forming the cushion material 178are contemplated for forming the surface covering elements.

[0068] 1. Use of standard filled Polyurethane system as the virginand/or rebond polyurethane. One contemplated polyurethane foam contains110 parts of filler and has a density of about 15 lbs/cu. ft. Based upona thickness in the range of 0.04-0.12 inches, using the density andfiller levels above, the weight range of the polymer is about 4.32 oz/sqyd to 12.96 oz/sq yd. The density can be lowered by lowering the amountof filler.

[0069] 2. Another option which would also work for the virgin and/orrebond polyurethane is to adjust the filler levels to reduce the densityto 13 lbs/cu. ft. At the same thickness limits the polymer weights wouldthen be 2.72-8.24 oz/sq. yd.

[0070] 3. Another option for the virgin and/or rebond polyurethane is touse an unfilled polyurethane (Prime urethane) system. High densitiessuch as above are not possible with prime however, they perform becauseof the wall structure and the fact that no filler is present. Based upona prime at 6 lbs/cu. ft. applied at the thickness limits above thepolymer weight would be 2.88-8.64 oz/sq. yd.

[0071] 4. Another option is to use a polyurethane system available underthe trade designation KANGAHIDE by Textile Rubber and Chemical Companywhich has only 15 parts of a filler material and is applied at 6-9lbs/cu. ft. density may be used. If a polymer calculation is again madeat the described thickness limits it would be 4.3-13.02 oz/sq. yd.

[0072] 5. Another option is to use a medium density or hybrid foamformed of mechanically frothed and chemically blown polyurethane foams.Such a mechanically frothed and chemically blown polyurethane foam isdescribed, for example, in U.S. Pat. No. 6,372,810 hereby incorporatedby reference herein.

[0073] The density of filled prime or virgin polyurethane foams can becontrolled by limiting the amount of filler. For example, one can reducethe filler content to produce a prime polyurethane foam of about 6 lb.per cubic foot density.

[0074] Although the above examples have to do with polyurethane, a waterbased foam system can also be used. For example, the foam may be an SBRfoam. Although a virgin polyurethane or polyurethane rebond foam orcompressed particle foam (formed of compressible particles, chips,crumbs, etc.) may be preferred, it is to be understood that othercompressible particles made from other foams (open cell, closed cell) ormaterials such as SBR foam, PVC foam, polyethylene foam, cork, rubber,crumb rubber, and/or the like may also be used. In particular, it iscontemplated that in place of foam, a felt or non-woven cushion may beutilized.

[0075] Regardless of the cushioning material used in the cushioningconstruction, it is contemplated that such material will preferably becharacterized by a compression modulus such that a relatively soft feelis imparted to the user. By way of example only, it is contemplated thatthe cushioning material will preferably be characterized by a 50%compression at a load of between about 5 and about 70 psi and morepreferably about 10 to about 30 psi when the isolated cushioningmaterial is measured according to ASTM specification D3574 Test C(Compression Force Deflection Test).

[0076] As previously indicated, surface covering elements of any of thedescribed constructions may include an optional backing layer 170 alsoreferred to as a release layer or secondary backing. The optionalbacking layer 170 may be a woven or non-woven textile fabric ofpolyester, polypropylene, polyester/polypropylene,polyester/polypropylene/acrylic, or other appropriate fibers or blendsand may contain a colorant, binder, or the like. According to onecontemplated practice, the backing layer 170 may be a non-wovenstructure or felt of polyester fiber and polypropylene fiber, with about50% -100% polyester. In another embodiment, a blend of 50% polyesterfiber, 20% polypropylene, and 30% acrylic fibers may be used. Thepolyester, polypropylene and/or acrylic fibers may be of one or moreselected colors to give the backing a desired color or appearance. Inone embodiment, foam forming the cushioning layer and the backing layer170 have a similar color. In a particular example, the foam and/orbacking have a green, blue, purple, gray, white, black, brown, or goldcolor. The color of the backing can be achieved, for example, by using awhite polyester fiber and a colored acrylic fiber or by using coloredpolyester and/or polypropylene fibers. In accordance with anotherexample, an amount of black polyester fibers is blended with an amountof white polyester fibers, an amount of colored polyester fibers, and anamount of white polypropylene fibers to form a non-woven colored backingmaterial or felt having the color of the colored polyester fibers andhaving a heathered or speckled look. The respective amounts of each typeor color of fiber are selected to give the desired color, brightness,shrink, etc.. The surface covering elements of any of the describedconstructions also preferably include a friction enhancing coating 180which may be applied in either a substantially continuous or patternedarrangement. By way of example only and not limitation, such frictionenhancing coatings may include latex, hot melt adhesives, siliconerubber, other rubbers, and the like. Also, although it is not preferred,the coating 180 may be covered with a release sheet, layer or film.

[0077] As will be appreciated, there exist a substantial number ofalternative embodiments and configurations for layered constructionsforming the surface covering elements for use in the flooring system ofthe present invention. By way of example only, in FIGS. 14A, 14B, 14Cand 14D wherein elements corresponding to those previously described aredesignated by like reference numerals in a 500 series, pileconstructions are illustrated corresponding substantially to those inFIGS. 13A-D respectively but wherein the reinforcing material 558 aspreviously described is held in suspended relation between layers of tiecoat material such as the hot melt adhesive previously described. Insuch a construction, it is contemplated that the tie coat material 560may be either in substantially discrete layers separated by thereinforcement material 558 or may migrate across the reinforcementmaterial 558. In either event, due to the substantial adhesion betweenthe tie coat material 560 and the reinforcement material 558, asubstantially stable load distribution layer 557 is nonethelessestablished in bonding relation between the primary pile fabric 512 andthe cushioning material 578.

[0078] In accordance with one example and with reference again to FIGS.14A-14D, the reinforcement material 558 may be a glass mat which is hotmelt laminated to the foam 578 by a hot melt layer 560.

[0079] As illustrated in FIGS. 15A, 15B and 15C, wherein like componentsto those previously described are designated by corresponding referencenumerals within a 600 series, it is contemplated that tufted loop pileand tufted cut pile constructions 610A and 610B may include a firstlayer of tie coat material 660 such as hot melt adhesive or the likeextending away from the primary backing 622 and into contact with asheet of reinforcement material 658 such as the non-woven glass or scrimmaterial previously described. Thus, the tie coat material 660 servesthe function of securing the tufts 620, 621 in place relative to theprimary backing 622 thereby avoiding the need to utilize a separatelatex or hot melt pre-coat. Accordingly, a single adhesive layer extendsbetween the upper surface of the reinforcement material 658 and theunderside of the primary backing 622. Of course, if desired a fictionenhancing coating 180 as previously described is disposed across theunderside of the backing 670.

[0080] As illustrated in FIGS. 16A, 16B and 16C wherein like componentsto those previously described are designated by corresponding referencenumerals within a 700 series, it is contemplated that tufted loop pileconstruction 710A, tufted cut pile construction 710B, and bonded cutpile construction 710C include a first layer of a tie coat material 760extending away from the upper surface of a layer of reinforcementmaterial 758 and which may be of a different character from a secondlayer of tie coat material 760′ extending away from the lower surface ofthe reinforcement material. In all other respects, the configuration issubstantially as illustrated and described in relation to FIGS. 15A, 15Band 15C respectively. By way of example only and not limitation, in theevent that the reinforcement material 758 is disposed between twodifferent adhesives, it is contemplated that the tie coat material 760extending away from the upper surface of the reinforcement material 758may be, for example, hot melt, while the tie coat material 760′extending away from the lower surface of the reinforcement material 758may be, for example, polyurethane forming composition, a low meltpowder, low melt fibers, a low melt film, or the like. Of course, thetie coat material 760 and/or 760′ may also comprise multiple layers ofthe adhesive. A fiction enhancing coating as previously described may bedisposed across the underside of the backing 770.

[0081] In FIGS. 17A, 17B and 17C wherein like components to thosepreviously described are designated by corresponding reference numeralswithin an 800 series, there are illustrated yet additional constructionsfor forming surface covering elements for use in covering a subfloorsupport surface 811. In such embodiments, tufted loop pile construction810A and tufted cut pile construction 810B, 810C include a layer ofreinforcement material 858 disposed between a first layer of latexadhesive 824 extending away from the upper side of the reinforcementmaterial 858 and a second layer of latex adhesive 824 extending awayfrom the lower side of the reinforcement material 858. Thus, latexextends substantially between the upper surface of the cushion material878 and the primary backing 822 with the layer of reinforcement material858 disposed within such latex at an intermediate position. Such latexis preferably a carboxilated styrene butadiene rubber (SBR) latex. Ofcourse it is also contemplated that similar constructions utilizingother adhesives such as Polyvinyl chloride (PVC), ethylene vinyl acetate(EVA), and acrylics as well as hot melts or polyurethanes as previouslydescribed may be useful. Of course, if desired a fiction enhancingcoating as previously described may be disposed across the underside ofthe backing 870.

[0082] As previously indicated, it is contemplated that additionalstability may be introduced by incorporating stabilizing elements inintimate relation to the primary backing of a tufted primary pilefabric. Exemplary embodiments incorporating such a configuration areillustrated in FIGS. 18A, 18B and 18C wherein like components to thosepreviously described are designated by corresponding reference numeralswithin a 900 series. As illustrated therein, tufted loop pileconstruction 910A and tufted cut pile construction 910B, 910C includepile forming yarns 920, 921, 921′ tufted through a primary backing 922which incorporates therein a primary backing stabilizing layer 923 suchas a woven or non-woven material or scrim. The primary backingstabilizing layer 923 may be adjoined to the primary backing 922 by aneedling or calendaring operation. In addition, point bonding may beachieved between the structures by incorporating heat activated adhesivefibers within the non-woven construction. In the event that aconstruction incorporating a primary backing stabilizing layer isutilized, it is contemplated that the pre-coat 924 and/or thereinforcement material 958 may be substantially reduced or eliminatedentirely if desired due to the stability imparted to the enhancedprimary backing 922, 923. A fiction enhancing coating 180 as previouslydescribed may be disposed across the underside of the backing 970.

[0083] As will be appreciated, while the secondary backing or felt maybe flame laminated to the underside of the construction, it is alsocontemplated that other attachment mechanisms may be used if desired. Byway of example only, it is contemplated that the secondary backing maybe joined to the underside by one or more layers of adhesive such as hotmelt adhesive or the like as previously described. Exemplary cut pileconstructions 1010A, 1010B for a surface covering element disposed inoverlying relation to a subfloor support surface 1011 are illustrated inFIGS. 19A and 19B, wherein elements corresponding to those previouslydescribed are designated by corresponding reference numerals within a1000 series. As illustrated, in each of those constructions a layer oflaminating adhesive 1060 is disposed between the cushioning material1078 and the secondary backing 1070. However, the secondary backing 1070may also be flame laminated or otherwise directly attached to thecushioning material if desired.

[0084] In accordance with yet another embodiment as shown in FIG. 20,which corresponds to FIG. 13D, and wherein like components aredesignated by like reference numerals within an 1100 series, thereinforcement material or layer 158 and the precoat layer 124 have beeneliminated. Thus, in this embodiment, the tie-coat layer 1160 such as aresilient adhesive extends between the primary carpet 1112 and thecushioning material 1178.

[0085] With reference to FIG. 21 which corresponds to FIG. 13D andwherein like components are designated by like reference numerals withinan 1200 series, still another embodiment is illustrated in which thebacking layer of felt or other material 170 of FIG. 13D has beeneliminated.

[0086] With reference to FIG. 22 which corresponds substantially to FIG.18, and wherein like components are designated by like referencenumerals within a 1300 series, reinforcement layer 958, and backinglayer 970 have been eliminated. The foam layer 1378 may be adhered tothe primary carpet fabric, for example, by flame lamination or by beingapplied directly thereto in a wet or uncured state and then cured. Ineach of the constructions illustrated in FIGS. 20, 21, and 22 a frictionenhancing coating composition 180 is disposed across the underside.

[0087] Of course, it is also contemplated that the surface coveringelements may be of a so called “hard back” construction which does notincorporate a foam layer. By way of example only, and not limitation,exemplary tufted and bonded constructions which do not incorporate afoam layer are shown in FIGS. 23A-23F.

[0088] In the tufted construction of FIG. 23A, the pile forming yarn1420A is tufted through a primary backing layer 1422A such as woven ornonwoven glass, spunbonded polyester or the like at a yarn density ofabout 16-24 ounces per square yard. A layer of precoat 1424A (about 16ounces per square yard) such as latex or PVC is disposed below theprimary backing layer 1422A to a layer of PVC (poly vinyl chloride) orhot melt 1460A. A layer of glass reinforcement (1458) (about 3 ouncesper square yard) is disposed between the layer 1460A and another layerof PVC or hot melt 1461A so as to form a stabilizing sandwich structure.The total combined mass of the first and second layers of PVC or hotmelt is preferably about 60 ounces per square yard. A friction enhancingcoating composition 180A is disposed across the underside.

[0089] The tufted construction 1410B illustrated in FIG. 23B isidentical to that illustrated in FIG. 23A but with the addition of alayer of felt 1470B or other surface conforming secondary backingmaterial overlying the friction enhancing coating composition 180B. Itis contemplated that such a layer of felt or other surface conformingmaterial may be beneficial in adapting the structure to placement acrossan irregular underlying support surface.

[0090] The tufted construction 1410C illustrated in FIG. 23C illustratesa simplified construction in which a tuft locking precoat layer 1424Csuch as latex, hot melt adhesive or the like extends away from theprimary backing 1422C to the secondary backing 1470C. A frictionenhancing coating 180C is disposed across the secondary backing 1470C.

[0091] The bonded construction 1410D illustrated in FIG. 23D includes asurface of bonded yarns 1434D having a pile density of about 29 ouncesper square yard projecting away from a primary backing layer 1438D ofglass having a mass per unit area of about 3 ounces per square yard.While the substrate layer 1438D is illustrated as a nonwovenconstruction, it is likewise contemplated that the substrate layer 1438Dmay be a woven construction if desired. As shown, the yarns 1434D areheld in place across the substrate layer 1438D by a bonding layer 1436of PVC or the like. According to one contemplated practice, the bondinglayer has a mass per unit area of about 60 ounces per square yard. Asillustrated, a first layer of PVC 1460D extends away from the substratelayer 1438D to an upper side of a stabilizing layer 1458D such as wovenor nonwoven glass with a second layer of PVC 1461D extending away fromthe lower side of the stabilizing layer 1458D. According to onecontemplated construction the first and second layers of PVC 1458D,1461D have a total combined mass of about 80 ounces per square yard andthe stabilizing layer has a mass per unit area of about 3 ounces persquare yard. A friction enhancing coating layer 180D is disposed acrossthe underside of the second layer of PVC 1461D.

[0092] The bonded construction 1410E illustrated in FIG. 23E isidentical to that illustrated in FIG. 23D but with the addition of alayer of felt 1470E or other surface conforming secondary backingmaterial overlying the friction enhancing coating composition 180. It iscontemplated that such a layer of felt or other surface conformingmaterial may be beneficial in adapting the structure to placement acrossan irregular underlying support surface.

[0093]FIG. 23F illustrates a tufted loop pile carpet tile construction1410F similar to that illustrated in FIG. 23C in which the primarycarpet 1412F includes a layer of PVC 1424F extending away from a primarybacking 1422F. One such PVC backed hard backed tile primary carpetconstruction 1412F which is well known is available from Toli Japan andhas a weight of about 1320 grams per square meter. The illustratedconstruction of FIG. 23F modifies such a traditional PVC hard backedconstruction by adding a friction enhancing coating 180F as will bedescribed further hereinafter which is resistant to PVC plasticizer andadditive migration and reaction.

[0094] It is also contemplated that a wide range of surface coveringelement constructions other than pile fabric may be utilized. By way ofexample only, and not limitation, various other constructions includesurface coverings of woven or non-woven fabric (including woven, knit,flocked, and needle punched fabrics and the like) hardwoods, ceramictile (and veneers emulating hardwoods and ceramic tile), glass, vinylcomposite tile, stone (such as marble, granite and the like), slab-likedecorative composites such as CORIAN® and the like as well as decorativelaminate sheeting such as linoleum and the like.

[0095] By way of example only and not limitation, in FIGS. 24, 24A and24B various surface covering constructions are illustrated whichincorporate a show fabric 1550 of nonwoven construction with a backinglayer of friction enhancing composition 180. As will be appreciated, theconstructions in FIGS. 24 and 24A are identical in all respects exceptthat in the construction of FIG. 24A a relatively thin layer of clearcovering material 1555 such as polyurethane or the like is disposedacross the surface of the show fabric 1550. As will be appreciated, sucha construction may provide additional protection against wear whilefacilitating the ability to roll office furniture and the like acrossthe surface.

[0096] In FIG. 24B a cushioned construction is illustrated wherein acushioning layer 1578 as previously described is incorporated into theconstruction. As will be appreciated, in these constructions thenon-woven show fabric provides a visually desirable visible show surfacewhich is held against lateral slippage by the friction enhancingcomposition 180.

[0097] A set of alternative constructions which utilize a woven orknitted show fabric 1650 is set forth at FIGS. 25, 25A and 25B whereinelements corresponding to those previously described are designated bylike reference numerals within a 1600 series. As will be appreciated, inthese constructions the woven or knitted show fabric provides a visuallydesirable visible show surface which is held against lateral slippage bythe friction enhancing composition 180. In FIGS. 25A and 25B arelatively thin layer of clear covering material 1655 such aspolyurethane or the like is disposed across the show fabric 1650.

[0098] A set of alternative constructions which utilize a napped wovenor knitted show fabric 1750 is set forth at FIGS. 26 and 26A whereinelements corresponding to those previously described are designated bylike reference numerals within a 1700 series. As will be appreciated, inthese constructions the napped show fabric 1750 provides a visuallydesirable visible show surface which is held against lateral slippage bythe friction enhancing composition 180.

[0099] An alternative construction which utilizes a wood or wood veneershow surface 1850 is set forth at FIG. 27 wherein elements correspondingto those previously described are designated by like reference numeralswithin an 1800 series. As will be appreciated, in this construction thewood or wood veneer show surface provides a visually desirable visibleshow surface which is held against lateral slippage by the frictionenhancing composition 180. If desired, one or more intermediate layersof felt, foam or combinations thereof may be disposed between the woodor wood veneer show surface 1850 and the friction enhancing composition180.

[0100] An alternative construction which utilizes a show surface 1950 ofceramic, stone, or a composite emulating ceramic or stone is set forthat FIG. 28 wherein elements corresponding to those previously describedare designated by like reference numerals within a 1900 series. As willbe appreciated, in this construction the show surface 1950 of ceramic,stone, or a composite emulating ceramic or stone provides a visuallydesirable visible show surface which is held against lateral slippage bythe friction enhancing composition 180. If desired, one or moreintermediate layers of felt, foam or combinations thereof may bedisposed between the show surface 1950 of ceramic, stone, or a compositeemulating ceramic or stone and the friction enhancing composition 180.

[0101] An alternative construction which utilizes a show surface 2050 oflaminate such as linoleum, vinyl composite tile or the like whereinelements corresponding to those previously described are designated bylike reference numerals within a 2000 series. As will be appreciated, inthis construction the show surface 2050 of synthetic laminate such aslinoleum, vinyl composite tile or the like provides a visually desirablevisible show surface which is held against lateral slippage by thefriction enhancing composition 180. If desired, one or more intermediatelayers of felt, foam or combinations thereof may be disposed between theshow surface 2050 of laminate such as linoleum, vinyl composite tile orthe like and the friction enhancing composition 180.

[0102] Of course, it is also contemplated that other constructions suchas foam or broadloom carpet with a layer of friction enhancingcomposition may likewise be utilized as a surface covering element. Byway of example only, in FIG. 30 there is illustrated a surface coveringelement 2110 in the form of an area rug disposed across a flooringsurface 2111.

[0103] An exemplary cross section of the area rug 2110 is shown in FIG.31. In the illustrated construction a pile yarn 2121 is tufted through aprimary backing 2122 as previously described and held in place by aprecoat layer 2124 of latex or other suitable material as previouslydescribed. Of course, it is to be understood that while the pile yarn2121 is shown as a cut pile, that a loop pile or other construction maylikewise be used.

[0104] In the illustrated arrangement a secondary backing 2170 isdisposed at a position below the precoat layer 2124. The secondarybacking is preferably a nonwoven material formed by suitable mechanical,chemical or thermal processing techniques such as a stitch bonded,hydro-entangled or needle punched textile structure. A continuous ordiscontinuous friction enhancing coating or griping layer 180 isdisposed across the underside. A stitch bonded textile may beparticularly preferred for the secondary backing 2170. Of course, it isto be understood that such stitch bonded and other nonwoven surfacecovering materials may be used on surface covering elements other thanarea rugs including any carpet or carpet tile construction as previouslydescribed.

[0105] The surface covering elements are preferably suitable forinstallation by a user with little or no experience with surfacecovering installations. Depending upon the construction of the surfacecovering element being used, it is contemplated that covering may takeplace across virtually any surface including floors, walls countertopsand the like. As previously indicated, so as to improve the ease ofinstallation, the surface covering elements disposed across the supportsurface are preferably resistant to sliding movement across the supportsurface once they are placed in position without the need for separatelyapplied adhesives. However, the surface covering elements are preferablyreadily displaceable vertically away from the support surface tofacilitate replacement or repositioning during installation. Inaccordance with potentially preferred constructions, the frictionenhancing coating is of a nature to facilitate the ability to lift andmove the surface covering element to various positions across thesupport surface a number of times without damaging either the surfacecovering element or the support surface. In addition, covering elementscan be removed or replaced at an extended time after installation. Thefriction enhancing coating disposed across the backing is preferably ofa character which does not permanently bond to the support surface. Inaddition, the friction enhancing coating does not permanently stick toitself so as to avoid undesired blocking attachment in back to backpackaging. Still further, the friction enhancing coating does not adhereto the show surface of the surface covering element so as to avoidundesired permanent adhesion if the surface covering elements are storedin roll form or stacked face to back. That is, the friction enhancingcoating provides lateral grip with little vertical stick and with littleor no blocking to itself or the face of the surface covering element.

[0106] It is to be understood that in any of the constructions as may beused, it is contemplated that the friction enhancing coating 180 may beapplied either in partial or complete covering relation to the backingso as to provide the desired level of friction with the support surface.In this regard it is contemplated that the friction enhancing coatingmay be applied in various patterns such that coated and uncoated regionsare cooperatively dispersed across the underside of the surface coveringelement. By way of example only, various exemplary patterns includewidthwise strips (FIG. 32); lengthwise strips (FIG. 33); dots or circles(FIG. 34); cross-hatching arrangements (FIG. 35); and serpentine stripes(FIG. 35). Of course, any other pattern may likewise be used.

[0107] The present invention may be further understood through referenceto the following nonlimiting examples

EXAMPLES 1-6

[0108] The evaluation of various friction enhancing coating materialswas carried out by conducting sliding friction and blocking tests inaccordance with the following procedures. Each of the tests was carriedout on samples of carpet tile having a construction substantially as setforth in Table 6 below. TABLE 6 (A) (B) 1. Product Type: ResidentialModular Floor Covering 2. Face: High Twist Frieze Cut pile 3. PrimaryBacking: Enhanced backing of woven polypropylene with needled andcalendared polyester and low melt polyester 4. Total Finished 39 oz/yd²Yarn Weight: 5. Stitches Per Inch: 7.69 6. Tufting Gauge: ⅛ 7. YarnPolymer: Nylon 6,6 8. Yarn Type: 1180 filament, with antistat, semi dulltrilobal, 17 dpf 9. Yarn Twist: 7.50 twist per inch in singles (S) andply (Z) 10. Yarn Ply: 2 ply twisted 11. Heatset: Yes, @ 260 to 264° F.with steam frieze 12. Yarn Size: 3.69/2 cotton count 13. Tufted Pile48/64 inches (¾″) Height: 14. Dyeing Method Jet Dye 15. PrecoatAdhesive: Styrene Butadiene Latex, 8 oz/yd² coating weight 16.Lamination Hotmelt with a bitumen and polypropylene resin TiecoatAdhesive: base, 17. Tiecoat Coating 46 oz/yd² Weight: 18. StabilizingFiberglass Mat, 2 oz/yd², modified acrylic binder Reinforcement: 19.Flame Lamination Fiberglass mat flame laminated to foam 20. CushionType: Rebond polyurethane foam, 15 millimeter uncompressed chip size 21.Cushion 7-8 millimeter (prelamination) Thickness 22. Cushion Density 6lbs/ft³ 23. Flame Lamination Felt flame laminated to foam 24. ReleaseLayer Nonwoven felt construction: 25. Release Layer 70% polyester/30%polypropylene blend composition 26. Release Layer 4 oz/yd² weight: 27.Modular Shape: 18″ square or nominal 23″ × 23″ two-side double chevron28. Modular Size: 18″ square or nominal 23″ × 23″ 29. Cutting Method:Controlled Depth cut from the back

[0109] Friction tests were performed by placing a 3″×3″ piece of coatedcarpet tile having a mass of about 22-24 grams on a smooth flat surface(a piece of laminate wood-like flooring). One end of the flat surfacewas raised at a rate of −10 degrees per second. The center of the carpettile was always placed 10 inches from the pivot point. The angle atwhich the carpet tile began to slip was recorded. No weight or pressurewas applied to the sample, and both surfaces were visually inspected tobe clean before the measurement was performed. Error bars are 5 degrees.

[0110] Instantaneous blocking tests were performed by placing twoidentically coated 3″×3″ carpet tiles back-to-back with a 5 pound massweight applied for 1 minute. A strip of aluminum foil was used to mask ½inch of one edge. The force required to pull the samples apart wasmeasured using an AccuForce III force meter from AMETEK. The sampleswere pulled apart by pulling on the edge carpet tufts from the maskedside of the tiles.

[0111] Elevated temperature blocking tests at 70 degrees C. (158 degreesF.) were performed by placing two identically coated 3″×3″ carpet tilesback-to-back with a 6.25 lb weight applied for at least 16 hours in a 70C. oven. A strip of aluminum foil was used to mask ½ inch of one edge.After removing from the oven, samples were allowed to cool. They werepulled apart by pulling on the edge carpet tufts from the masked side ofthe tiles using an AccuForce III force meter from AMETEK. The peak forceneeded to separate the tiles was recorded.

[0112] Re-Stick friction tests were conducted to determine thereusability of the carpet friction enhancing or grip layer. A 3″×3″piece of coated carpet was placed on clean, laminate, wood-like flooringwith a 5-lb weight applied. After 30 seconds, the weight and carpet weremoved to a fresh section of the flooring. This was repeated such thatthe carpet was exposed to 5 positions. The results of a friction test asdescribed above were then recorded.

[0113] Pressure sensitive friction tests were performed by placing a 5lb weight on a 3″×3″ piece of coated carpet on glass for 30 seconds.After removal of the weight, an inclined plane friction test wasperformed.

[0114] Adhesion to glass tests were measured using an AccuForce IIIforce meter from Ametek. A 5-lb weight was applied to 3″×3″ back-coatedcarpet samples on glass for 30 seconds. The peak force required toremove the sample from the glass by pulling on the edge was recorded.

[0115] Results are set forth in table 7 below. TABLE 7 Re- FrictionStick Dry Instantaneous 70 deg C. on Re-Stick Glass Press. FrictionGlass add-on Blocking Blocking Laminate Friction Friction Sensitive OnAdhesion Sample (gsm) (lbs) (lbs) (degrees) (degrees) (degrees) FrictionGlass (lbs) Latex 1 30 <0.7 <0.7 85 80 >90 >90 >90 0.4 Latex 2 20 0.71.3 48 45 48 >90 50 0.4 Latex 3 30 4.8 60 58 85 60 0 Hot Melt 1 20 <0.72.7 45 45 45 50 50 0 Hot Melt 2 45 <0.7 1.5 45 62 >90 65 0.2 Hot Melt 335 <0.7 0.9 58 80 >90 >90 0.3 Control 0 <0.7 <0.7 20 20 20 20 20 0

[0116] All carpet samples (3″×3″) weighed 22-24 g.

[0117] Latex 1=National Starch & Chemical Multilock 454A

[0118] Latex 2=Rohm and Haas Robond PS-68

[0119] Latex 3=Air Products Airflex TL12

[0120] Hot Melt 1=HB Fuller, HL 6102

[0121] Hot Melt 2=HB Fuller, HL 5062

[0122] Hot Melt 3=The Reynolds Company, Reynco 53-343

[0123] Based upon these tests it was concluded that Latex 1, Latex 2,Hot Melt 2 and Hot Melt 3 exhibited desirable friction and anti-blockingcharacteristics with Latex 3 and hot melt 1 being less desirable. Morespecifically, samples with elevated temperature blocking less than about3 lbs in combination with substantial sliding friction were believed tobe desirable. Samples such as hot melt 2 which exhibit substantialincreases in sliding friction following pressure application may beparticularly desirable. Of course, the samples tested are merelyrepresentative and other suitable coating materials no doubt exist.Exemplary materials may include various classes of latex includingacrylics, EVA, SBR, and the like and hot melt materials includingpolyolefins, EVA, SBR, polyamides, and the like. Potentially preferredcoating materials may include latex or olefin based hot melt materialssuch as olefins based on polypropylene and/or polyethylene andpotentially including low molecular weight waxes and tackifiers. The dryadd-on ranges should preferably be about 0.25 to about 3 ounces persquare yard and more preferably about 0.5 to about 1.5 ounces per squareyard.

[0124] The friction enhancing coatings may be applied to the back of thesurface covering elements by various methods including roll coating,spray coating, impregnation, powder coating, and printing methods. Afterapplication of the coating, a drying and or curing process may be useddepending on the form of the coating chosen. Coating may be eithercontinuous or patterned across the underside of the surface coveringelement.

EXAMPLES 7 AND 8

[0125] A carpet construction as set forth in Table 6 above was testedfor vertical stick and resistance to lateral movement relative tovarious underlying support surfaces. Tests were conducted with a barefelt backing and with a friction enhancing coating of a hot meltmaterial marketed by H.B. Fuller Company under the trade designation HL5062 applied across a felt backing at a coating weight of 1.0 ounces persquare yard.

[0126] Vertical adhesion measurements were made using a 6.75 inch×6.75inch piece of coated carpet tile placed on each designated surface. A 25pound weight was placed on top of each sample to insure uniform contactwith the surface. After 30 seconds the weight was removed and the samplewas grabbed at yarns in the middle and lifted away from the surface. Thepeak force required to separate the tile sample from the surface wasmeasured using a Shimpo FGE-100X Digital Force Gauge. The measurementwas repeated 10 times and the average force value was recorded.

[0127] Resistance to lateral movement measurements were made using an 18inch×18 inch piece of coated carpet tile placed on each designatedsurface. An 8.5 pound aluminum plate with an arrangement of downwardlyprojecting pile engaging pins was placed on top of each sample to ensureuniform contact with the surface. The peak force required to move thetile sample laterally across the surface for a distance of 1 inch wasmeasured using a Model STE-1000 Testron Tensile Tester. The measurementwas repeated 10 times and the average force value was recorded.

[0128] The results are set forth in Tables 8 and 9 below. TABLE 8(Coated Cushion Backed Samples) Unsealed Wood Sealed Concrete GlassPlywood Concrete Direction Units Support Support Support Support SupportVertical Lbs.-Total 1.490 1.180 0.550 0.590 0.44 Adhesion Lbs./Inch²0.033 0.026 0.012 0.013 0.010 Resistance Lbs.-Total 37.2 22.2 30.8 19.210.8 to Lateral Lbs./Inch² 0.115 0.069 0.095 0.059 0.033 Movement

[0129] TABLE 9 (Uncoated Cushion Backed Control Samples) Sealed ConcreteGlass Direction Units Support Support Vertical Adhesion Lbs.-Total 0.3100.300 Lbs./Inch² 0.007 0.007 Resistance to Lbs.-Total 1.1 2.69 LateralLbs./Inch² 0.003 0.028 Movement

EXAMPLES 9-22

[0130] The test procedures of Examples 7 and 8 were carried out oncarpet tile samples using other hot melt coatings. Comparison tests weremade for each coating using several different coating weights rangingfrom 1.0 to 2.5 ounces per square yard. Performance using differenttypes of felt backings (T1 felt versus T2 felt) was also evaluated. Theresults are set forth in Table 10 below: TABLE 10 COMPARISONS OF HOTMELT ADHESIVES AND FELTS Dry Add- Shear Strength Tensile On (lbs/18″Shear Strength Strength Product (oz/sq yard) Type Backing square)(lbs/inch²) (lbs/inch²) Reynolds 53- 1.0 Felt - T1 9.0 0.028 <0.03 451 AReynolds 53- 1.6 Felt - T1 8.9 0.027 <0.03 451 A Reynolds 53- 1.0 Felt -T1 15.3 0.047 <0.03 451 B Reynolds 53- 1.5 Felt - T1 11.4 0.035 <0.03451 B Reynolds 53- 2.5 Felt - T1 12.1 0.037 <0.03 451 B Reynolds 53- 1.0Felt - T1 17.4 0.054 <0.03 451 C Reynolds 53- 1.5 Felt - T1 14.3 0.044<0.03 451 C Reynolds 53- 1.0 Felt - T1 9.8 0.030 <0.03 451 D Reynolds53- 1.5 Felt - T1 9.5 0.029 <0.03 451 D Reynolds 53- 2.5 Felt - T1 9.60.030 <0.03 451 D H.B. Fuller 1.0 Felt - T2 22.2 0.069 <0.03 5062 H.B.Fuller 1.5 Felt - T2 19.8 0.061 <0.03 5062 Reynolds 53- 1.0 Felt - T244.3 0.136 <0.03 451 C Reynolds 53- 1.5 Felt - T2 43.2 0.133 <0.03 451 C

[0131] In each example, coated tiles did not permanently bond to commonsub-floor surfaces. Coated tiles exhibited sufficiently high resistanceto lateral movement to prevent the tile from easily sliding and alsoexhibited low vertical adhesive properties (tack) that allowed tiles toeasily be lifted from place.

[0132] In particular, it was concluded that a hot melt coating materialunder the trade designation Reynolds 53-451C, comprised essentially of amixture of polypropylene, polyethylene and selected tackifying agentsthat have a high propensity to wet concrete surfaces, exhibitedsignificantly higher resistance to lateral tile movement for concretesurfaces than other tested products.

[0133] Further, the above tests demonstrate that the nature of the feltbacking to which the coating is applied may improve the performance ofthese coatings in terms of their resistance to lateral movement (shearstrength) with no corresponding change in vertical adhesion (shearstrength). In particular, it was found that so called “type T2” feltprovided superior resistance to lateral movement with the same coatingaddition. By T2 felt is meant felt that is predrafted and ellipticallyneedled.

[0134] The type T2 felt in the above examples is formed by needling apredrafted fibrous web of about 60% polyester fibers having a lineardensity of about 4 denier and a staple length of about 3 inches andabout 40% polypropylene fibers having a linear density of about 5 denierand a staple length of about 4 inches using three needling machinesincorporating elliptical needle movement. More specifically, the blendof fibers (60% polyester and 40% polypropylene) is subjected to adrafting operation as will be well known to those of skill in the artprior to needling which aligns and stretches the fibers such that theweb exiting the drafting station is about 1.8 times the length of theweb entering the drafting station. It is believed that the comparativetype T1 felt (available from Synthetic Industries in Dalton Ga., USA)utilizes the same fibrous blend but without a drafting treatment priorto needling.

[0135] The type T2 felt is passed through three needling machines whichutilize elliptical needle movement. The comparative type T1 felt isformed at two needling machines which use a straight reciprocatingmotion. In the formation of the type T2 felt the elliptical needlingmachines permit the needles to move with the web at substantially thesame speed as the web while nonetheless penetrating the web to entanglethe fibers. Conversely, in the straight reciprocating motion used toform the type T2 felt, the needles do not move in the direction of theweb.

[0136] According to one contemplated practice in forming the type T2felt, the first needling machine utilizes about 3857 needles per meterper board mounted on four boards disposed above and below the travelpath of the web and which move in elliptical travel paths so as to causethe outwardly projecting needles to penetrate and withdraw from the webso as to cause entanglement and web densification. The needles in thefirst needling machine are preferably 40 gauge triangle needles. Thesecond and third needling machines also incorporate 3857 needles permeter per board but use only the top two boards (i.e. the boardsdisposed above the web). The needles in the second needling machine are38 gauge star needles and the needles in the third needling machine are42 gauge triangle needles. In formation of the comparative type T2 feltthe first needling machine uses 5000 needles up and 7000 needles downwhile the second needling machine uses 7000 needles up and 7000 needlesdown.

[0137] Although the precise mechanism which causes the type T2 felt toexhibit improved performance is not fully understood, it is believedthat the predrafting of the fibrous web prior to needling in combinationwith the elliptical needling entanglement may provide a higher surfacearea for attachment of the coating material. Thus, the coating isdeposited across a complex matrix structure. This avoids film formation,on the contact surface thereby maintaining an irregular high surfacearea for contact with the floor or other underlying structure. Thus, theimproved performance is understood to result from the higher surfacearea and the fact that the coating material may be concentrated withinthe high surface area fiber matrix.

[0138] In various carpeting structures as described above, thepredrafting in combination with elliptical needling entanglement alsoserves to form a structure which is more resistant to penetration fromthe top by the urethane or other overlying material. This avoids asituation in which the urethane or other material seals the felt. Suchsealing may promote undesirable film formation when the frictionenhancing coating is applied. Thus, by reducing penetration from theoverlying urethane or other material, the desired high contact surfaceis promoted.

EXAMPLES 23-26 (COMPARATIVE)

[0139] Using the test procedures of Examples 7 and 8 comparison testswere made comparing shear strength (i.e. resistance to lateral movement)of friction enhancing coating Reynolds 53-451C relative to prior artmodular adhesive techniques of applying pressure sensitive releasableadhesives to an underlying floor prior to installing an overlying carpettile and so called “Peel & Stick” techniques wherein pressure sensitiveadhesives are applied to the back surface during manufacturing with anoverlying protective plastic film to prevent tiles from stickingtogether prior to installation. The results are set forth in thefollowing table. Shear Tensile Strength Strength Shear Strength(lbs/inch²) (lbs/inch²) (lbs/18″ square) Milliken Modular Adhesive 0.3240.066 105.0 Shaw Carpet - Peel & Stick 0.164 0.182 53.3 C&S Carpet -Peel & Stick 0.152 0.090 49.1 Reynolds 53-451 C 0.136 <0.030 44.3

[0140] Based on the above tests, it was concluded that hot meltcoatings, like or similar to Reynolds product 53-451C, when applied tospecific types of felt carpet tile backings, exhibit high shearstrengths equivalent to prior art methods as manufacturer appliedadhesives (Peel & Stick) with lower vertical adhesion properties.

[0141] The following benefits and advantages are contemplated for theabove mentioned coatings, in particular in the context of 36 inchcushion carpet tile products.

[0142] 1. Carpet tile products requiring no wet adhesive forinstallation, either applied to the under lying floor prior tooverlaying carpet tile or as pressure sensitive adhesive applied duringthe manufacturing process with an overlying protective plastic film areprovided.

[0143] 2. Carpet tile products with high shear strength for preventingslippage between the floor covering and low tensile strength tofacilitate removal and replacement of the floor covering are providedwithout the need for an overlying protective plastic release film thatmust be removed prior installing the tile. Such character lends to theelimination of packaging waste and cost for the same.

[0144] 3. Carpet tile products that can be installed over concretesurfaces with moisture levels up to 8.0 lbs/1000 sq ft/24 hours, basedon the industry standard calcium chloride test, that exceeds the currentacknowledged industry standard of 3.0 lbs/1000 sq ft/24 hours areprovided.

[0145] 4. Carpet tile products that can be installed over most old(non-solvent based) adhesives with residual tack levels =/<0.20-lbs/sqinch without extensive floor preparation to sand, remove or seal oversuch adhesives are provided.

EXAMPLES 27 AND 28 (HARD BACKED CARPET)

[0146] Vertical adhesion and resistance to lateral movement weremeasured for tufted and bonded hard backed carpet constructions relativeto a glass surface using the procedures outlined with respect toExamples 7 and 8 above.

[0147] The bonded carpet construction was substantially as illustratedin FIG. 23D with a pile face of nylon yarn (about 29 ounces per squareyard), a bonding layer of PVC (about 60 ounces per square yard), aprimary backing layer of glass (about 3 ounces per square yard), and anunderlying supporting sandwich structure of glass (about 3 ounces persquare yard) between two layers of PVC having a combined mass of about80 ounces per square yard. In the coated specimen a friction enhancingcoating of HB Fuller, HL 5062 (olefin hot melt) was coated across thelower PVC surface at a level of about 1.2 ounces per square yard.

[0148] The tufted carpet construction was substantially as illustratedin FIG. 23A with a pile face of nylon yarn (about 24 ounces per squareyard), a primary backing of spunbonded polyester, a layer of latexprecoat ((about 16 ounces per square yard), and a sandwich structure ofglass (about 3 ounces per square yard) between two layers of PVC havinga combined mass of about 60 ounces per square yard. In the coatedspecimen a friction enhancing coating of HB Fuller, HL 5062 hot melt wascoated across the lower PVC surface at a level of about 1.2 ounces persquare yard.

[0149] The results are set forth in Table 11. TABLE 11 (Hard-Back CarpetTile on Glass) Bonded Tufted Uncoated Carpet Carpet Direction UnitsBonded (Coated) (Coated) Vertical Lbs.-Total 0.280 0.300 0.300 AdhesionLbs./Inch² 0.007 0.007 0.007 Resistance Lbs.-Total 2.69 39.6 37.8 toLateral Lbs./Inch² 0.008 0.122 0.117 Movement

[0150] While excellent results were achieved using the olefin hot meltcoating across the PVC, it is contemplated that latex or other waterbased adhesives may provide substantial benefits in such applications.

EXAMPLES 29-32 (NON-CARPET TILE MATERIALS)

[0151] The following examples exhibit lateral grip, optional bondcleavage strength and low back to back adhesion of various non-carpetsurface covering materials in both coated and uncoated conditions.

[0152] A friction enhancing olefin based hot melt coating, H.B. FullerHL 5062, was applied to common hard surface materials using a top rollapplicator. The friction enhancing properties were then evaluated bymeasuring the resistance to lateral movement (bond shear strength) andvertical adhesion (bond cleavage strength) of each sample using a glasssurface according to the procedures described below. Additionalmeasurements were made to determine the adhesion between two coatedsamples after the coated surfaces were placed in contact.

[0153] Cleavage adhesion measurements were made using pieces of coatedhard surface materials placed on a glass surface. Each sample overlappedthe glass surface, a distance of 1″, thereby providing a surface againstwhich a force could be applied to separate the sample from the glasssurface and measure the result cleavage force. A 25 lb weight was placedon top of each sample to insure uniform contact with the surface. After30 seconds, the weight was removed and the peak force required toseparate the sample from the surface measured using a Shimpo FGE-100XDigital Force Gauge. In each case, the separating force was appliedpushing up on the overlap lip perpendicular ( 90°+/−5°) to the testedsample. The measurement was repeated 5 times and the average force valuethen recorded. Measurement were made for control samples (uncoated)using the same method and then compared to the coated materials.

[0154] Resistance to lateral movement measurements were made usingpieces of coated hard surface materials placed on a glass surface. A 25lb weight was placed on top of each sample to insure uniform contactwith the surface. After 30 seconds, the weight was removed and the peakforce required to move or push the sample laterally across the glasssurface measured using a Shimpo FGE-100X Digital Force Gauge. In eachcase, the force was applied as a pushing force to the center edge of thesample with a downward an angle of 25°+/−5°. The measurement wasrepeated 5 times and the average force value then recorded. Measurementwere made for control samples (uncoated) using the same method and thencompared to the coated materials.

[0155] Adhesion between samples was measured by placing two pieces ofcoated hard surface materials with their respective coated surfaces incontact so as to evaluate blocking character. The samples wereoverlapped, a distance of 1 inch relative to one another therebyproviding a surface against which a force would be applied to separatethe samples. A 25 lb weight was placed on top of the sample and removedafter 30 seconds. The force required to separate the samples wasmeasured using a Shimpo FGE-100X Digital Force Gauge. In each case, theseparating force was applied along the overlap lip perpendicular(90°+/−5°) to the tested sample. The measurement was repeated 5 timesand the average force value then recorded.

[0156] The results are set forth at tables 12 (coated samples) and 13(uncoated control samples) below. TABLE 12 MEASUREMENTS OF HARD SURFACEMATERIALS - COATED Units Vinyl Tile Ceramic Tile Laminate Flooring WoodFlooring Horizontal Bond Lbs-Total 32.4 28.1 >100.0 >100.0 Lbs-Inch²0.225 0.781 >1.667 >0.790 Cleavage Bond Lbs-Total 1.60 0.60 1.50 1.70Lbs-Inch Width 0.133 0.100 0.188 0.151 Adhesion Lbs-Total 1.80 1.70 1.101.70 Lbs-Inch Width 0.150 0.283 0.138 0.151 Sample Size Inches 12 × 126.0 × 6.0 8 × 7½ 11¼ × 11¼ Sample Weight Gms 635 267 286 686 Dry Add OnGms/Sq Foot 4.0 8.0 9.5 4.6

[0157] TABLE 13 MEASUREMENTS OF HARD SURFACE MATERIALS - CONTROLS UnitsVinyl Tile Ceramic Tile Laminate Flooring Wood Flooring Horizontal BondLbs-Total 0.55 0.30 0.50 1.30 Lbs-Inch² 0.046 0.050 0.063 0.116 CleavageBond Lbs-Total 1.0 0.30 0.70 0.90 Lbs-Inch 0.083 0.050 0.088 0.080 Width

EXAMPLES 33-40 (PVC BACKED CARPET TILE)

[0158] In order to evaluated suitability of various friction enhancingcoatings for use on PVC hardback carpet tiles, chemical compatibilitywith PVC backings under accelerated aging conditions was measured for anumber of friction-enhancing coating compositions. Chemicalcompatibility for various friction-enhancing coatings was evaluatedusing accelerated aging to measure the effects of the aging process forcoatings applied across a PVC backed carpet tile using a standard PVCbacked primary carpet tile Style GA-100 from Toli Japan having aconstruction substantially as illustrated and described in relation toFIG. 23F with a total weight of 1320 gms/sq meter. These tests indicatewhether or not the friction-enhancing coating is adversely affected dueto the migration of plasticizers or additive chemicals from the PVCcarpet tile body into the adjoining coating over time. Undesirablemigration is designated by an “F” while lack of migration is designatedby a “P”

[0159] Test material was prepared by applying each friction-enhancingcoating to the back surface of the PVC backed carpet tile using aconventional top roll applicator. As applicable, some samples receivedpost treatment, either UV curing or drying, necessary to chemicallycross-link the base polymer. Details are provided in Table 14, whichlists and describes each product evaluated. Coating weights ranged from1.0 to 1.5 oz/sq yard (3.2-4.7 gms/sq foot), resulting in a coatingthickness of 1.5-2.5 mils.

[0160] In order to reflect a range of actual long term uses, twodifferent accelerated aging tests were utilized as outlined below.

[0161] Accelerated Aging Test #1

[0162] 1. Coated PVC backed carpet tile were cut into 4″×4″ testsquares. Three samples sets were prepared for each coating material byplacing two (2) carpet squares back to back. A two (2) Kilogram weightwas placed on top of each sample set.

[0163] 2. Each sample set was placed in a conventional laboratory ovenmaintained at 160° F.

[0164] 3. Individual sample sets were removed from the oven at intervalsof 24, 48 and 72 hours and inspected for evidence of chemical reactionsor bonding between the individual layers due to plasticizer or additivemigration. Friction properties were evaluated by conducting slidefriction tests across various surfaces.

[0165] Accelerated Aging Test #2

[0166] 1. Coated PVC backed carpet tile were cut into 4″×4″ testsquares. Sample sets were prepared placing two (2) carpet squares backto back. A two (2) Kilogram weight was placed on top of each sample set.

[0167] 2. Each sample set was placed in a conventional laboratory ovenmaintained at 120° F. for a period of twenty-one days.

[0168] 3. The samples sets were inspected for evidence of chemicalreactions or bonding between the individual layers due to plasticizer oradditive migration. Friction properties were evaluated by conducting aslide friction test.

[0169] Thus, Test #1 was conducted at a higher temperature for shorterperiods of time, while Test #2 was conducted at a lower temperature fora longer period of time. The results are summarized in Table 13 below. Apassing result was achieved if there was no indication of chemicalreaction or change in coating properties following the test. Conversely,a visible indication of chemical reaction and/or change in coatingproperties resulted in a failing result.

[0170] Based on these tests it was concluded that several modified orcross-linked urethane coatings exhibited excellent resistance to PVCplasticizers and additive reactions. Likewise, certain acrylate hot meltcompounds exhibited excellent resistance to PVC plasticizers andadditive reaction. TABLE 14 CHEMICAL COMPATIBILITY WITH PVC BACKEDCARPET TILE ACCELERATED AGING PRODUCT COMPOUND BASE POST TREATMENTADD-ON 24 HR 48 HR 72 HR 21 DAY H.B. FULLER 5062 POLYOLEFIN POLYMERS HOTMELT - NONE 1.0 F F F F NORTHWEST 50587G CROSS-LINK URETHANE UV CURED1.1 P P P P NORTHWEST 50587H CROSS-LINK URETHANE UV CURED 1.0 P P P PCTI 3603 CROSS-LINK URETHANE FORCED AIR OVEN 1.0 P P P P ROBOND PS-68ACRYLIC POLYMERS FORCED AIR OVEN 1.2 F F F F CTI 2743 ACRYLIC POLYMERSFORCED AIR OVEN 1.2 F F F F REYNOLDS 531 C POLYOLEFIN POLYMERS HOTMELT - NONE 1.0 F F F F H.B. FULLER 6599 ACRYLATE POLYMERS HOT MELT -NONE 1.1 P P P P

[0171] H.B. Fuller 5062 and 6599—Available from H.B. Fuller Co.;

[0172] Northwest 50587G and 50587H—Available from Northwest Coatings inOak Creek Wis.;

[0173] CTI 3603 and 2743—Available from Chemical Technologies Inc. inDetroit Mich.;

[0174] Robond PS-68—Available from Rohm and Haas Chemicals;

[0175] Reynolds 531 C—Available from The Reynolds Company;

EXAMPLES 41-48

[0176] Friction enhancing properties for various coatings showingchemical compatibility with PVC (i.e. those that passed the ageing testsabove) were measured across various flooring surfaces (concrete, wood,glass, aluminum and steel) and compared to a Toli GA-100 PVC hard backedtile without a friction enhancing coating. Vertical stick of the coatedtiles and an uncoated control sample on these surfaces was alsomeasured. The testing procedures utilized for measuring friction andvertical stick as set forth in Examples 7 and 8 above were utilized. Theresults are set forth in Table 15 below. TABLE 15 PRODUCT UNITS CONCRETEWOOD GLASS ALUMINUM STEEL LATERAL RESISTANCE NORTHWEST 50587G 1.1 OZ/YD²lbs/18″ sq 15.1 20.5 21.6 19.4 17.3 lbs/inch² 0.047 0.063 0.067 0.0600.053 CTI 3603 1.2 OZ/YD² lbs/18″ sq 31.8 33.3 31.5 33.0 21.8 lbs/inch²0.098 0.103 0.097 0.102 0.067 H.B. FULLER 6599 1.2 OZ/YD² lbs/18″ sq20.6 21.9 15.8 46.0 22.8 lbs/inch² 0.064 0.068 0.049 0.142 0.070 CONTROLlbs/18″ sq 12.7 12.3 12.3 13.3 10.7 lbs/inch² 0.039 0.038 0.038 0.0410.033 VERTICAL ADHESION NORTHWEST 50587G 1.1 OZ/YD² lbs/6.75″ sq <0.3<0.3 <0.3 <0.3 <0.3 lbs/inch² <0.007 <0.007 <0.007 <0.007 <0.007 CTI3603 1.2 OZ/YD² lbs/6.75″ sq <0.3 <0.3 <0.3 <0.3 <0.3 lbs/inch² <0.007<0.007 <0.007 <0.007 <0.007 H.B. FULLER 6599 1.2 OZ/YD² lbs/6.75″ sq<0.3 <0.3 <0.3 <0.3 <0.3 lbs/inch² <0.007 <0.007 <0.007 <0.007 <0.007CONTROL lbs/6.75″ sq <0.3 <0.3 <0.3 <0.3 <0.3 lbs/inch² <0.007 <0.007<0.007 <0.007 <0.007

[0177] Based on the above tests, it was concluded that the coatingslisted in Table 15 exhibited desirable properties, such that coatedtiles did not permanently bond to common sub-floor surfaces whilenonetheless exhibiting sufficiently high resistance to lateral movementto prevent the tile from easily sliding or moving. Further, the coatingexhibited low vertical adhesive properties (tack), desirable propertiesthat allow the tile to easily be lifted from place.

[0178] Of course, it is to be understood that such friction enhancingcoatings are in no way limited to hardback PVC carpet tile. Rather, itis contemplated that such friction enhancing coatings may be used withany cushioned or hardback carpet tile as well as with other non-carpetsurface coverings as described herein. The present invention thusprovides numerous surface covering elements which incorporate a frictionenhancing coating across a lower surface. Surprisingly, it has beenfound that such friction enhancing coatings may provide desiredresistance to lateral slip while nonetheless avoiding a high degree ofvertical stick to the underlying support surface (such as a floor,counter top, wall, etc.). This resistance to vertical stick aids inreplacement of the covering elements following installation while alsoavoiding the need to incorporate a peel away covering sheet forpackaging installation. The friction enhancing coating also ischaracterized by low adherence to itself (i.e. it is substantiallynon-blocking) thereby permitting back to back packaging. Moreover,coatings have been identified which are fully compatible withtraditional PVC backings as are used in hard backed carpet tile.

[0179] Of course, it is to be understood that while the presentinvention has been illustrated and described in relation to potentiallypreferred embodiments, constructions and practices, that suchembodiments, constructions and practices are intended to be illustrativeonly and that the invention is in no event to be limited thereto.Rather, it is contemplated that modifications and variations embodyingthe principles of the present invention will no doubt occur to those ofskill in the art and it is therefore contemplated and intended that thepresent invention will extend to all such modifications and variationsas may incorporate the broad principles of the present invention.

What is claimed is:
 1. A surface covering element adapted fordisposition in covering relation to a support surface wherein saidsurface covering element comprises: a show surface adapted to projectaway from the support surface when the surface covering element isdisposed across the support surface; and an underside adapted to projecttowards the support surface when the surface covering element isdisposed across the support surface, wherein a friction enhancingcoating composition is disposed in coated relation across the undersideat an effective level to enhance sliding friction of the surfacecovering element such that the surface covering element exhibits adegree of lateral grip across the support surface which is substantiallygreater than the lateral grip exhibited by a surface covering element ofidentical construction without the friction enhancing coating andwherein the friction enhancing coating composition does not permanentlystick to the support surface and provides the surface covering elementwith an amount of vertical stick or adhesion with little or no blocking.2. The invention as recited in claim 1, wherein the friction enhancingcoating composition is disposed across the underside of said surfacecovering element at a dry add-on level of not greater than about 50grams per square meter.
 3. The invention as recited in claim 1, whereinthe friction enhancing coating composition is disposed across theunderside of said surface covering element at a dry add-on level of notgreater than about 30 grams per square meter.
 4. The invention asrecited in claim 1, wherein the friction enhancing coating compositionis disposed across the underside of said surface covering element at adry add-on level of not greater than about 20 grams per square meter. 5.The invention as recited in claim 1, wherein the friction enhancingcoating composition is a latex composition.
 6. The invention as recitedin claim 5, wherein the latex composition is an acrylic latexcomposition.
 7. The invention as recited in claim 5, wherein the latexcomposition is an EVA latex composition.
 8. The invention as recited inclaim 5, wherein the latex composition is an SBR latex composition. 9.The invention as recited in claim 1, wherein the friction enhancingcoating composition is a hot melt composition.
 10. The invention asrecited in claim 9, wherein the hot melt composition is an olefincomposition.
 11. The invention as recited in claim 10, wherein theolefin composition is based on one of polypropylene and polyethylene.12. The invention as recited in claim 1, wherein the show surfaceadapted to project away from the support surface is a textile selectedfrom the group consisting of carpet fabric, woven fabric, knit fabric,nonwoven felt, flocked fabric and napped pile fabric.
 13. The inventionas recited in claim 2 wherein the surface covering is a cushioned carpetfabric selected from the group consisting of broadloom carpet, runners,area rugs, and modular carpet tile.
 14. The invention as recited inclaim 12 wherein the show surface is a carpet fabric and wherein thesurface covering is selected from the group consisting of broadloomcarpet, runners, area rugs, and modular carpet tile, and wherein thecarpet fabric has a backing comprising at least one layer of PVC . 15.The invention as recited in claim 1, wherein the show surface adapted toproject away from the support surface comprises a vinyl surface.
 16. Theinvention as recited in claim 1, wherein the show surface adapted toproject away from the support surface comprises a ceramic surface. 17.The invention as recited in claim 1, wherein the show surface adapted toproject away from the support surface comprises a laminate surface. 18.The invention as recited in claim 1, wherein the show surface adapted toproject away from the support surface comprises a wood surface.
 19. Theinvention as recited in claim 1, wherein the surface covering elementincludes at least one layer of foam cushioning.
 20. The invention asrecited in claim 1, wherein the surface covering element is at least oneof flooring, counter top, or wall covering.
 21. The invention as recitedin claim 1, wherein the surface covering element has a vertical adhesionof at least 0.01 lbs/inch².
 22. The invention as recited in claim 1,wherein the surface covering element has a vertical adhesion of at least0.02 lbs/inch².
 23. The invention as recited in claim 1, wherein thesurface covering element has a vertical adhesion of at least 0.03lbs/inch².
 24. The invention as recited in claim 1, wherein the surfacecovering element has a vertical adhesion of less than 0.04 lbs/inch².25. A surface covering element adapted for disposition in coveringrelation to a support surface of any of the group consisting ofconcrete, wood, glass, aluminum or steel, wherein said surface coveringelement comprises: a show surface adapted to project away from thesupport surface when the surface covering element is disposed across thesupport surface; and an underside of PVC adapted to project towards thesupport surface when the surface covering element is disposed across thesupport surface, wherein a friction enhancing coating composition isdisposed in coated relation across the underside at an effective levelto enhance sliding friction of the surface covering element such thatthe surface covering element exhibits a degree of lateral grip crossacross the support surface which is substantially greater than thelateral grip exhibited by a surface covering element of identicalconstruction without the friction enhancing coating and wherein thefriction enhancing coating composition does not stick to the supportsurface.
 26. The invention as recited in claim 25, wherein the frictionenhancing coating composition is disposed across the underside of saidsurface covering element at a dry add-on level of about 0.5 to about 1.5ounces per square yard.
 27. The invention as recited in claim 1, whereinthe friction enhancing coating composition is a cross linked urethane.28. The invention as recited in claim 27, wherein the cross linkedurethane is an ultra-violet cured urethane.
 29. The invention as recitedin claim 27, wherein the cross linked urethane is a heat cured urethane.30. The invention as recited in claim 1, wherein the friction enhancingcoating is an acrylate hot melt composition.
 31. The invention asrecited in claim 25, wherein the show surface adapted to project awayfrom the support surface is a textile selected from the group consistingof carpet fabric, woven fabric, knit fabric, nonwoven felt, flockedfabric and napped pile fabric.
 32. The invention as recited in claim 25,wherein the surface covering element is a cushioned carpet fabricselected from the group consisting of broadloom carpet, runners, arearugs, and modular carpet tile.
 33. The invention as recited in claim 25,wherein the show surface adapted to project away from the supportsurface comprises a vinyl surface.
 34. The invention as recited in claim25, wherein the show surface adapted to project away from the supportsurface comprises a ceramic surface.
 35. The invention as recited inclaim 25, wherein the show surface adapted to project away from thesupport surface comprises a laminate surface.
 36. The invention asrecited in claim 25, wherein the show surface adapted to project awayfrom the support surface comprises a wood surface.
 37. A surfacecovering element comprising a hardback carpet tile adapted fordisposition in covering relation to a support floor of any of the groupconsisting of concrete, wood, glass, aluminum and steel, wherein saidsurface covering element comprises: a show surface of outwardlyprojecting pile yarns adapted to project away from the support floorwhen the surface covering element is disposed across the support floor;and an underside of PVC adapted to project towards the support floorwhen the surface covering element is disposed across the support floor,wherein a friction enhancing coating composition is disposed in coatedrelation across the underside of PVC at an effective level to enhancesliding friction of the surface covering element relative to the supportfloor such that the surface covering element exhibits a degree oflateral grip cross across the support floor which is substantiallygreater than the lateral grip exhibited by a surface covering element ofidentical construction without the friction enhancing coating andwherein the friction enhancing coating composition does not permanentlystick to the support surface and wherein the friction enhancing coatingcomposition is selected from the group consisting of cross-linkedurethane and acrylate hot melt polymers.
 38. The invention as recited inclaim 1, wherein the friction enhancing coating composition comprisessilicone rubber.
 39. The invention as recited in claim 1, wherein thefriction enhancing coating is coated in a discontinuous pattern acrossthe underside.
 40. The invention as recited in claim 25, wherein thefriction enhancing coating is coated in a discontinuous pattern acrossthe underside.
 41. The invention as recited in claims 37, wherein thefriction enhancing coating is coated in a discontinuous pattern acrossthe underside.
 42. The invention as recited in claim 1, wherein theunderside comprises felt.
 43. The invention as recited in claim 42,wherein the felt is a predrafted elliptically needled felt.
 44. Theinvention as recited in claim 25, wherein the underside comprises felt.45. The invention as recited in claim 44, wherein the felt is apredrafted elliptically needled felt.
 46. The invention as recited inclaims 37, wherein the underside comprises felt.
 47. The invention asrecited in claim 46, wherein the felt is a predrafted ellipticallyneedled felt.